Fan housing

ABSTRACT

Embodiments of the present disclosure include a fan housing having a first part with a first side wall and a first back wall, a second part having a second side wall and a second back wall, where the first back wall and the second back wall meet to define an axle opening and the first and second side walls meet to define a right circular cylinder parallel with the axle opening. The first part and second part of the housing can be mirror images when positioned with the first and second sidewalls and the edge of the first and second back walls facing each other. Embodiments of the fan housing can also include a motor casing that extends from the first and second back walls away from the first and second side walls. The motor casing can contain and house a motor for turning the impeller contained in the housing.

A fan is a device used to induce airflow and is generally made from broad, flat surfaces which revolve or oscillate. The most common applications of fans are for ventilation and/or for gas transport for industrial purposes.

There are three main types of fans used for moving air: axial, centrifugal (also called radial) and cross flow (also called tangential). The axial-flow fans have blades that force air to move parallel to the shaft about which the blades rotate. Axial fans blow air linearly across the axis of the fan. This is the most common type of fan, and is used in a wide variety of applications, ranging from small cooling fans for electronics to the giant fans used in wind tunnels.

The centrifugal fan has a moving component called an impeller that consists of a central shaft about which a set of blades form a spiral pattern. Centrifugal fans blow air at right angles to the intake of the fan, and spin (centrifugally) the air outwards to the outlet. An impeller rotates, causing air to enter the fan near the shaft and move perpendicularly from the shaft to the opening in the scroll-shaped fan housing. A centrifugal fan produces more pressure for a given air volume, and is used where this is desirable.

The cross flow fan has a squirrel cage rotor (a rotor with a hollow center and axial fan blades along the periphery). Cross flow fans take in air along the periphery of the rotor, and expel it through the outlet in a similar fashion to the centrifugal fan. Cross flow fans give off an even airflow along the entire width of the fan, and are very quiet in operation. They are comparatively bulky, and the air pressure is low.

Each of the above fan types has a fan housing. The fan housing serves to house the fan blades and/or impellers and direct fluid flow from the fan blades and/or impellers. A variety of fan housing designs have been proposed for improving air flow and reducing noise produced by the fan. These fan housing, however, can be complex in both their design and configuration. As a result, improvements to fan housing designs are needed.

BRIEF DESCRIPTION OF THE DRAWINGS

The Figures presented herein provide illustrations of non-limiting example embodiments of the present disclosure. The Figures are not necessarily to scale.

FIG. 1 illustrates an exploded view of one embodiment of a fan housing according to the present disclosure.

FIG. 2 illustrates an exploded view of one embodiment of a fan housing according to the present disclosure.

FIG. 3 illustrates an exploded view of one embodiment of a fan housing according to the present disclosure.

FIG. 4 illustrates one embodiment of a fan housing according to the present disclosure.

FIG. 5 illustrates one embodiment of a fan housing according to the present disclosure.

FIG. 6 illustrates an exploded view of one embodiment of a fan having a fan housing, an impeller, and motor according to the present disclosure.

DETAILED DESCRIPTION

Embodiments of the present disclosure include fan housings, fans each with a fan housing, and methods of making the fan housings of the present disclosure. As used herein, fan housings include, but are not limited to, structures that at least partially surround an impeller or a fan blade to help direct the flow of a fluid through the fan. Fluids as used herein can include, but are not limited to, gases and/or liquids. It will be apparent to those skilled in the art that the following description of the various embodiments of this disclosure are provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

The Figures herein follow a numbering convention in which the first digit or digits correspond to the drawing figure number and the remaining digits identify an element in the drawing. Similar elements between different figures may be identified by the use of similar digits. For example, 102 may reference element “102” in FIG. 1, and a similar element may be referenced as “202” in FIG. 2. As will be appreciated, elements shown in the various embodiments herein can be added, exchanged, and/or eliminated so as to provide a number of additional embodiments. The elements and/or embodiments illustrated in the figures are not to scale.

In describing the various embodiments herein, the following directional terms “annular,” “axial,” “circumferential,” “radial,” “longitudinal” and “transverse” as well as other similar directional terms may be used. As used herein, these directional terms as well as other directional terms are made relative to a center rotational axis of an axle that can rotate an impeller or fan blade at least partially housed in the fan housing according to various embodiments of the present disclosure. Accordingly, these terms, as used to describe various embodiments should be interpreted relative to the center rotational axis of the axle. The axle may be coupled to the impeller through a central hub of the impeller. Alternatively, the axle may be part of and extend from the impeller to be coupled to, for example, a motor. In addition, the figures presented herein provide illustrations of non-limiting example embodiments.

Embodiments of the present disclosure include, but are not limited to, a fan housing that includes, among other things, a first part having a first side wall and a first back wall, a second part having a second side wall and a second back wall, where the first back wall and the second back wall meet to define an axle opening and the first side wall and the second side wall meet to define a right circular cylinder parallel with the axle opening. In one embodiment, the first part of the housing can be a mirror image of the second part when positioned with the first and second sidewalls and the edge of the first and second back walls facing each other.

Embodiments of the present disclosure can further include a motor casing that extends from the first and second back walls away from the first and second side walls. The motor casing can contain and house a motor for turning the impeller contained in the housing of the present disclosure. In one embodiment, the motor casing can include a first section that extends from the first back wall and a second section that extends from the second back wall, where the first section and the second section are mirror images of each other.

FIG. 1 provides an exploded view of one embodiment of a fan housing 100 according to the present disclosure. The fan housing 100 includes a first part 102 and a second part 104. In one embodiment, the first part 102 includes a first side wall 106 and a first back wall 108, and the second part 104 includes a second side wall 110 and a second back wall 112. When the first and second parts 102, 104 are brought together they meet along an edge 114 that helps define an axle opening 116.

As discussed herein, the axle opening 116 can receive an axle that joins to an impeller or a fan blade at least partially housed in the fan housing 100. In one embodiment, the axle opening can receive a rotary or a roller bearing that can seat in the axle opening 116 and through which an axle attached to the impeller can pass.

In addition to defining the axle opening 116, the first and second side walls 106 and 110 also have surfaces that define a right circular cylinder that extends parallel (i.e., in the same direction) with the walls defining the axle opening 116. So, for example, the first and second side walls 106, 110 extend orthogonally relative the first and second back walls 108, 112. In one embodiment, the axle opening 116 can be centrically positioned relative the first and second side walls 106 and 110. In an alternative embodiment, the first and second side walls 106 and 110 can define a portion of a right circular cone, where the side walls 106, 110 can taper or flare either towards or away from each other as they extend from the back walls 108, 112.

In an additional embodiment, the first and second side walls 106 and 110 have surfaces with a contour that allow a radial edge of an impeller or the fan blade to rotate past the side walls 106 and 110 at a predetermined distance. In other words, a gap can be maintained between the edge of the impeller and the side walls 106, 110. For example, the predetermined distance between the radial edge of the impeller and the side walls 106, 110 can be essentially uniform.

Alternatively, the predetermined distance can be a minimum distance that is maintained between a portion of the side walls 106, 110 and the outer edge of the impeller or fan blade, where other portions of the side walls 106, 110 have a predetermined distance that is greater than the minimum distance. In other words, the side walls 106, 110 can define a non-cylindrical shape in which an impeller rotates. In addition, the side walls 106, 110 need not be planar, as illustrated. Alternatively, the side walls 106, 110 can have a curvature that provide for a convex or a concave shape as the side walls 106, 110 extend from the back walls 108, 112 in the longitudinal direction of the axle opening 116.

Regardless of the configuration, the first part 102 of the housing 100 can be a mirror image of the second part 104 when the two parts are positioned with the first side wall 106 and the second side wall 110 facing each other. In other words, the first and second parts 102, 104 can be symmetrical, where the different portions of the parts 102, 104 correspond in size, shape, and relative position of the different portions on opposite sides of a dividing line (the axis of the impeller axle or a medial plane dividing the parts 102, 104). This is in contrast to other fan housing designs that may be divided along another axis that does not provide for this symmetry. The symmetry in the part 102, 104 provided by the present disclosure provides for a more efficient manufacturing and assembly of the fan housing as there is no need to differentiate one side of the fan housing from another.

The housing 100 can further include an outlet port 118 provided through one of the first side wall 106 and the second side wall 110. In one embodiment, the outlet port 118 provides an exit pathway for fluid being moved by an impeller to leave the fan housing 100. In one embodiment, the housing 100 can initially be formed without the outlet port 118, thereby providing the symmetry in the parts 102, 104. The outlet port 118 can then be formed through one of the side walls 106, 110 at a location that is suitable for the users intended purpose. In other words, the outlet port 118 can be formed at a number of different locations in the side walls 106, 110 so as to accommodate a number of different applications.

In one embodiment, the ability to select the location of the outlet port 118 is afforded due to the material used to form the first and second parts 102, 104 of the housing 100. In one embodiment, the housing 100 can be formed from a polymer and/or copolymer, including thermoplastics and/or thermoset materials. Combinations of these materials can also be used in forming the first and second parts 102, 104. In one embodiment, materials for the first and second parts 102, 104 can be selected from those having thermally insulative properties, electrically insulative properties, anti-static properties, or combinations thereof. In addition, the materials for the first and second parts 102, 104 can be selected from those suitable for use as an explosion proof housing (e.g., sufficient shear strength at suitable material thickness for forming the parts 102, 104). The material used to form the parts 102, 104 can also be coated with a number of different treatments. These can include, but are not limited to, anti-biological coatings and/or anti-static coatings. Other coating materials are also possible.

As discussed, the outlet port 118 can be formed in a number of different locations on either of the first and/or second parts 102, 104. In addition, the shape and size of the outlet port 118 can be configured based on the application and/or the additional ducting or connections that are to be made to the housing 100. For example, in one embodiment the outlet port 118 can be made by cutting through the first and/or second side wall 106, 110 of the housing 100 at the desired location. In one embodiment, an outlet port for fluid flow can be formed by cutting through one of the first or second side walls 106, 110 to form an opening of desired size and shape.

In one embodiment the first and second parts 102, 104 of the housing can be joined along the edge 114. In one embodiment, the housing 100 can be joined along edge 114 by bonding the first and second parts 102, 104 together. For example, a chemical adhesive (e.g., a glue) can be used to join the first and second parts 102, 104. Examples of such adhesives include, but are not limited to, cyanoacrylates (e.g., methyl-2-cyanoacrylate) and resins such as epoxy resins. Alternatively, the first and second parts 102, 104 can be joined by fusing the two parts together. For example, the first and second parts 102, 104 formed from a thermoplastic could be joined using an ultrasound welding process. Other welding techniques for different materials used to form the first and second parts 102, 104 are also possible.

Alternatively, the first and second parts 102, 104 can be releasably joined along the edge 114. For example, the first and second parts 102, 104 can include tongue and groove guides along or adjacent the edge 114 to position the parts 102, 104 in a proper relationship and one or more releasable fasteners that join the two parts 102, 104.

In one embodiment, the first and second parts 102, 104 can each be formed in a single contiguous piece. For example, each of the parts 102, 104 can be formed in a mold having a cavity defining the shape of the first and second parts 102, 104. The first and second parts 102, 104 can then be formed through an injection molding process using either a thermoplastic or a thermoset material. In one embodiment, the injection molding process can be either a high pressure or a low pressure process that depends upon the type of polymer material being used to form the parts 102, 104.

In addition, additional parts and/or portions not formed of the polymer material can be included with the first and second parts 102, 104. For example, the additional parts and/or portions can be positioned in the mold used to form the part 102, 104 either before, during, or after the molding process. So, for example, a roller bearing could be molded into a portion of the axle opening 116 of either of the first and second parts 102, 104. Other examples include, but are not limited to, one or more mounting brackets that can join either or both of the first and second parts 102, 104.

FIG. 2 provides an exploded view of an additional embodiment of a fan housing 200 according to the present disclosure. The housing 200 includes the first and second parts 202, 204 having the first and second side walls 206, 210 and the first back wall 208 and the second back wall 212. In the present embodiment, the first and second back walls 208, 212 have a non-planar configuration. For example, the first and second back walls 208, 212 illustrated in FIG. 2 define a concave surface.

In one embodiment, the shape of the first and second back walls 208, 212 can correspond to the shape of a base plate for an impeller. So, for example, the base plate of the impeller could have a curved surface that corresponds in shape to the non-planar configuration of the first and second back walls 208, 212 (e.g., the base plate of the impeller could maintain a predetermined distance from the first and second back walls 208, 212). In an alternative embodiment, the curvature of the back walls 208, 212 in relation to the base plate of the impeller can be used in forming and configuring the plenum defined by the first and second parts 202, 204 of the housing 200 (e.g., the base plate of the impeller does not maintain a predetermined distance from the first and second back walls 208, 212).

FIG. 3 provides an exploded view of another embodiment of a fan housing 300 according to the present disclosure. The housing 300 includes the first and second parts 302, 304 having the first and second side walls 306, 310 and the first back wall 308 and the second back wall 312. In the present embodiment, the first and second back walls 308, 312 have a non-planar configuration. For example, the first and second back walls 308, 312 illustrated in FIG. 3 defines a convex surface.

As discussed herein, the base plate of an impeller could be configured to correspond with the curvature of the first and second back walls 308, 312 (e.g., the base plate of the impeller could maintain a predetermined distance from the first and second back walls 308, 312). In an alternative embodiment, the curvature of the back walls 308, 312 in relation to the base plate of the impeller can be used in forming and configuring the plenum defined by the first and second parts 302, 304 of the housing 300 (e.g., the base plate of the impeller does not maintain a predetermined distance from the first and second back walls 308, 312).

FIG. 4 provides an additional embodiment of the fan housing 400 according to the present disclosure. The perspective view in FIG. 4 is of a backside of the fan housing 400, a view that is opposite those illustrated in FIGS. 1-3. The fan housing 400 includes the first part 402 with the first back wall 408 and the second part 404 with the second back wall 412. The fan housing 400 also includes the axle opening 416 defined by the edge 414 of the first and second parts 402, 404.

The fan housing 400 further includes one embodiment of a motor casing 420 that extends from the first and second back walls 408, 412 away from the first and second side walls 406, 410. The embodiment of the motor casing 420 illustrated includes a motor support 422 and casing walls 424. In one embodiment, a motor attached to an impeller passing through the axle opening 416 can be mounted to the motor support 422 in a number of different ways. For example, the motor support 422 can define openings 426 therethrough to receive and pass mounting bolts to secure the motor to the motor support 422. Alternatively, the motor support 422 can include a mounting bracket to which the motor can be secured. The motor support 422 could also include other motor mounting hardware specific to receive and hold the motor in the appropriate place relative the axle opening 416 and the other parts of the fan housing 400.

FIG. 5 provides an additional embodiment of the fan housing 500 according to the present disclosure. As illustrated, the fan housing 500 includes the first part 502 and the second part 504 having the motor casing 520. The embodiment of the motor casing 520 illustrated in FIG. 500 extends from the first and second back walls 508, 512 away from the first and second side walls 506, 510.

The motor casing 520 also includes a first section 528 that extends from the first back wall 508 and a second section 530 that extends from the second back wall 512. In one embodiment, the first and second sections 528, 530 join along the edge 514 to encase the motor. In addition, the first and second parts 502, 504, including the first and second sections 528, 530 are mirror images of each other when positioned with the first and second sidewalls 506, 510 and the edge 514 of the first and second back walls 508, 512 facing each other.

FIG. 6 provides an exploded view of a fan 632 according to the present disclosure. The fan 632 includes the fan housing 600 with first and second parts 602, 604, first and second sections 628, 630, a motor 634, and impeller 636. The impeller 636 is coupled to an axle 638 that extends through the axle opening 616 to couple to the motor 634. The motor 634 can cause the axle 638 and the impeller 636 to rotate so as to move fluid through the fan housing 600. In one embodiment, the motor 634 can be an electric motor having a power cord coupled to the motor and a mechanical and/or electrical control mechanism to turn the motor 634 on or off and to control the rotational speed of the motor 634.

As illustrated, the motor 634 can be located on the motor support 622 and be encased by the motor casing 620. In the present embodiment, the motor casing 620 includes the first and second sections 628, 630 that encase the motor 634. As illustrated, the fan housing 600 surrounds at least a portion of the impeller 636 to define a plenum from which fluid is moved through the outlet port 618. As discussed herein, the first and second parts 602, 604 of the fan housing 600 can join at the edge 614 that intersects the axle 638. In one embodiment, the edge 614 can bisect the axle 638.

As discussed herein, the first part 602 and the second part 604 are mirror images of each other that define the axle opening 616 when the two parts 602, 604 are joined at the edge 614. In one embodiment, the axle opening 616 can completely surrounds the axle 638. The fan housing 600 can also include the first side wall 606 and the second side wall 610 that, in one embodiment, define a right circular cylinder parallel with the axle opening 616 through the housing 600. As discussed herein, the side walls 606, 610 can also define additional shapes for the plenum of the fan housing 600.

The fan housing 600 can further include the motor support 622, as discussed herein, to which the motor 634 can be releasably coupled. The fan housing 600 is also illustrated as including the motor casing 620 that surrounds at least a portion of the motor 634. In the present embodiment, the motor casing 620 is configured to include the first and second sections 628, 630 that are used to encase the motor 634. Other configurations are possible.

As illustrated, the impeller 636 includes a base plate 640 and fan blades 642 that extend from the base plate 640. In one embodiment, the fan blades 642 and the base plate 640 can be formed as a single piece. One approach to forming the fan blades 642 and the base plate 640 in a single piece is through a molding process, such as injection molding or through a casting process. Alternatively, the base plate 640 and fan blades 642 can be separate pieces that are joined to form the impeller 636.

The embodiment of the impeller 636 illustrated in FIG. 6 can be useful with centrifugal fans that receive airflow into the impeller axially, and redirect the airflow radially outward through, for example, outlet port 618. Alternatively, the impeller 636 and the housing 600 of the present disclosure can also be useful with mixed flow fans, which are characterized in that the air enters the impeller 636 axially and is deflected at an obtuse angle by the fan blades such that the air flowing out of the impeller 636 has both axial and radial flow components. In an additional embodiment, the fan 632 can be configured as an axial flow fan (back wall 608, 612 has additional openings through which fluid can flow along the axial direction—flow through the impeller 636 in a direction generally parallel to the axle axis).

In addition, a variety of fan blades 642 can be used with the impeller 636 of the fan 632. Such fan blades include those used in radial blade fans, radial tip fans, airfoil fans, backwardly inclined flat fan, and forward-curved-blade centrifugal fans. Housings, impellers and/or fans of the present disclosure can also be used in a number of different applications including, but not limited to, those that require explosion proof fans, fans used in food handling facilities/applications (e.g. a food grade fan), fans for use in toxic (e.g., biological and/or chemical) environments, and fans for use in flammable environments. Use of the embodiments of the present disclosure is also possible with other types of fans.

In one embodiment, the materials from which the housing, impeller and motor allow for the fan to be autoclaved, mechanically destroyed (e.g., shredded, pulverized, etc.), incinerated, or otherwise destroyed if necessary. A possible reason for having to destroy the fan includes reducing the volume of the fan structure for long term storage if the fan was to become contaminated with radiation or biological contaminates.

The fan 632 can further include a shroud 644. In one embodiment, the shroud 644 extends between the first side wall 606 and the second side wall 610, and has an opening to allow fluid flow in a direction of the axle 638 into the fan housing 600. In addition, the housing 600 of the fan 632 can further include support members that extend between, for example, each of the first and second sections 628, 630 and the casing walls of the motor casing 620. In one embodiment, the support members can help to brace and support the housing 600.

Methods and processes for forming the fan housing and various components of the fan housing described herein are provided as non-limiting examples of the present invention. As will be appreciated, a variety of molding processes exist that can be used to form the components of the fan housing. Examples of such molding processes can include resin transfer molding, compression molding, transfer molding, and injection molding, among others.

Other fabrication processes are possible to form the components of the fan housing. For example, components of the fan housing could be cast, milled, molded, and/or cut. In addition, the components of the fan housing of the present disclosure can be formed from a number of different materials. For example, the components could be formed from metal, metal alloys, and polymers, including thermoplastics and/or thermoset materials.

Methods of the present disclosure include those of forming the various components and features of the fan housing of the present disclosure. For example, the first and second parts of the fan housing can be formed using a fabrication technique and materials discussed herein to each have the side wall and the back wall. As discussed herein, the first and second parts of the housing are symmetrical (e.g., mirror images of each other taken along the edge where they will be joined to form the fan housing). Similarly, the first and second sections of the motor casing can be molded with the first and second parts, and then joined to form the fan housing of the present disclosure. As with the first and second parts, the first and second sections of the motor casing are mirror images of each other.

In addition, the first and second parts are not initially formed with the fluid opening. This allows the end user to select and cut the outlet port through the wall of one of the first part and the second part of the fan housing that will be most useful give the specific application of the fan housing.

The first and second parts, optionally including the first and second sections, can then be joined along the edge using, for example, the techniques discussed herein. In joining the first and second parts, the axle opening, discussed herein, is formed. The axle opening can then, for example receive, or be formed with, a bearing through which the axle extends. Alternatively, the axle opening can be formed without a bearing. As will be appreciated, the motor, axle, and impeller can be added to and joined with the fan housing so as to form the fan discussed herein.

While the present disclosure has been shown and described in detail above, it will be clear to the person skilled in the art that changes and modifications may be made without departing from the spirit and scope of the disclosure. As such, that which is set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. The actual scope of the disclosure is intended to be defined by the following claims, along with the full range of equivalents to which such claims are entitled. In addition, one of ordinary skill in the art will appreciate upon reading and understanding this disclosure that other variations for the disclosure described herein can be included within the scope of the present disclosure. 

1. A fan housing, comprising: a first part having a first side wall and a first back wall; and a second part having a second side wall and a second back wall, where the first back wall and the second back wall meet to define an axle opening and the first side wall and the second side wall define a right circular cylinder parallel with the axle opening.
 2. The fan housing of claim 1, where the first part is a mirror image of the second part.
 3. The fan housing of claim 1, including an outlet port cut through one of the first side wall and the second side wall.
 4. The fan housing of claim 1, where the first back wall and the second back wall define a concave surface.
 5. The fan housing of claim 1, where the first back wall and the second back wall define a convex surface.
 6. The fan housing of claim 1, further including a shroud that extends between the first side wall and the second side wall, the shroud having an opening to allow fluid flow in a direction of the axle into the fan housing.
 7. The fan housing of claim 1, including a motor casing that extends from the first and second back walls away from the first and second side walls.
 8. The fan housing of claim 7, where the motor casing includes a first section that extends from the first back wall and a second section that extends from the second back wall.
 9. The fan housing of claim 8, where the first section and the second section are mirror images of each other.
 10. A fan, comprising a motor; an axle coupled to the motor, where the axle rotates; an impeller coupled to the axle; and a housing that surrounds at least a portion of the impeller, the housing having a first part and a second part that join at an edge that intersects the axle.
 11. The fan of claim 10, where the first part and the second part are mirror images of each other.
 12. The fan of claim 10, where the edge bisects the axle.
 13. The fan of claim 10, where the first part and the second part when joined at the edge define an axle opening that completely surrounds the axle.
 14. The fan of claim 13, where the first part of the housing includes a first side wall and the second part includes a second side wall, and the first and second side walls define a right circular cylinder parallel with the axle opening through the housing.
 15. The fan of claim 10, where the housing includes a motor support to which the motor is releasably coupled.
 16. The fan of claim 15, where the housing includes a motor casing that surrounds at least a portion of the motor.
 17. A method of forming a fan housing, comprising: molding a first part of the fan housing; molding a second part of the fan housing, where the second part is a mirror image of the first part; and joining the first part and the second part along an edge that meets at an axle opening defined by the first part and the second part.
 18. The method of claim 17, where molding the first part and the second part includes using a thermoset material to mold the first part and the second part.
 19. The method of claim 17, including cutting an outlet port through a wall of one of the first part and the second part.
 20. The method of claim 17, including molding a first section and a second section of a motor casing; and joining the first and second sections of the motor casing to the first part and the second part of the fan housing.
 21. The method of claim 20, including molding the first section and the second section of the motor casing as mirror images of each other.
 22. The method of claim 17, where joining the first part and the second part along the edge includes fusing the first part to the second part along the edge. 